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Main Shaft Assembly: Assembly

WARNING: This page is about a different car, the 2001 Subaru Impreza. However, it is still accessible from the selected car via links, so may be relevant.
  1. Assemble sleeve and hub assembly for 3rd-4th and, 5th synchronizing.
    NOTE: Position open ends of spring 120° apart.
    Fig 1: Assembling Sleeve And Hub Assembly For 3rd-4th And, 5th Synchronizing
    G02060232
  2. Install 3rd drive gear, outer baulk ring, synchro cone, inner baulk ring, sleeve and hub assembly for 3rd needle bearing on transmission main shaft.
    NOTE: Align groove in baulk ring with shifting insert.
    Fig 2: Installing 3rd Drive Gear, Outer Baulk Ring, Synchro Cone And Related Components Onto Transmission Main Shaft
    G02060233
  3. Install 4th needle bearing race onto transmission main shaft using ST1, ST2 and a press.
    CAUTION: Do not apply pressure in excess of 10 kN (1 ton, 1.1 US ton, 1.0 Imp ton).

    ST1 899714110 REMOVER

    ST2 499877000 RACE 4-5 INSTALLER

    Fig 3: Install 4th Needle Bearing Race Onto Transmission Main Shaft
    G02060234
  4. Install baulk ring, needle bearing (32 x 30 x 25.7), 4th drive gear and 4th gear thrust washer to transmission main shaft.
    NOTE: Align baulk ring and gear & hub assembly with key groove.
    Fig 4: Installing Baulk Ring, Needle Bearing, 4th Drive Gear And Related Components Onto Transmission Main Shaft
    G02060235
  5. Drive ball bearing onto the rear section of transmission main shaft using ST1, ST2 and a press.
    CAUTION: Do not apply pressure in excess of 10 kN (1 ton, 1.1 US ton, 1.0 Imp ton).

    ST1 899714110 REMOVER

    ST2 499877000 RACE 4-5 INSTALLER

    Fig 5: Pressing Ball Bearing Onto The Rear Section Of Transmission Main Shaft
    G02060236
  6. Using ST1 and ST2, install the 5th gear thrust washer and 5th needle bearing race onto the rear section of transmission main shaft.
    CAUTION: Do not apply pressure in excess of 10 kN (1 ton, 1.1 US ton, 1.0 Imp ton).
    NOTE: Face thrust washer in the correct direction.

    ST1 899714110 REMOVER

    ST2 499877000 RACE 4-5 INSTALLER

    Fig 6: Installing 5th Gear Thrust Washer And 5th Needle Bearing Race Onto The Rear Section Of Transmission Main Shaft
    G02060237
  7. Install bearing onto synchro cone.
    NOTE: Align baulk ring and gear & hub assembly with key groove.
  8. Install baulk ring and synchro cone onto 5th-Rev sleeve and hub assembly using ST and a press.
    CAUTION: Do not apply pressure in excess of 10 kN (1 ton, 1.1 US ton, 1.0 Imp ton).
    NOTE:
    • Use new ball bearing.
    • After press fitting, make sure synchro cone rotates freely.

    ST 499757002 SNAP RING PRESS

    Fig 7: Installing Baulk Ring And Synchro Cone Onto 5th-Rev Sleeve And Hub Assembly
    G02060238
  9. Install synchro cone stopper and snap ring to 5th-Rev sleeve and hub assembly.
    Fig 8: Installing Synchro Cone Stopper And Snap Ring To 5th-Rev Sleeve And Hub Assembly
    G02060239
  10. Install the rest of parts to the rear section of transmission main shaft.
    NOTE: Align groove in baulk ring with shifting insert.

    ST1 499987003 SOCKET WRENCH

    ST2 498937000 TRANSMISSION HOLDER

    Fig 9: Installing Rest Of Components To Rear Section Of Transmission Main Shaft
    G02060240
  11. Tighten lock nuts to the specified torque using ST1 and ST2.
    NOTE: Secure lock nuts in two places after tightening.

    ST1 499987000 SOCKET WRENCH

    ST2 498937000 TRANSMISSION HOLDER

    Tightening torque:  118 N.m (12.0 kgf-m, 86.8 ft-lb)

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